Flexible hermetic semiconductor solar cell package with non-hermetic option
A device containing a solar cell chip that may include a hermetically sealed chamber containing optical matching fluid and a threaded pedestal mounting to allow for replacement of solar cell units and that are easily mountable to a master heat sink.
Latest Solar Junction Corporation Patents:
This application was filed contemporaneously with U.S. Provisional Patent Application No. 61/439,095, filed on Feb. 3, 2011, entitled “FLEXIBLE HERMETIC SEMICONDUCTOR SOLAR CELL PACKAGE WITH NON-HERMETIC OPTION” and U.S. Provisional Application No. 61/439,082, filed on Feb. 3, 2011, entitled “INTEGRATED SEMICONDUCTOR SOLAR CELL PACKAGE,” the contents of which are incorporated herein by reference in their entirety.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENTNot Applicable
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISKNot Applicable
BACKGROUND OF THE INVENTIONThis invention relates to packaging for semiconductor photovoltaic devices known generally as solar cells.
Photovoltaic devices present unique problems requiring specialized packaging to achieve desired levels of durability, mechanical integrity, electrical connectivity, maximum thermal transfer, and convenience of mounting. The packaging must also lend itself to a low cost and highly automated manufacturing process. The delicate semiconductor material used as the operative portion of a solar cell must be protected from excessive current by attaching, for example, an additional device such as a bypass diode in parallel with the anode and cathode of the device, an operation normally accomplished by soldering surface mount plastic packaged devices in a manner that may cause high rates of mechanical failure in actual usage. Further, suppliers of photovoltaic cells and systems are increasingly required to guarantee that their products will operate without replacement for long periods of time, in some cases up to 30 years or more. The packaging for such cells must therefore provide durability as well as reliability.
Current solar cell package designs suffer from design and component limitations that restrict package usage. For example, solar cell packaging to date has relied on ceramics such as aluminum nitride (ALN) and berrylium oxide (BeO) to provide thermally conductive substrates between the heat sink and solar cell. Because of the limited number of suppliers, use of these ceramic substrates increases the cost of manufacturing the solar packaging. Commercialized solar packages also require that the chip, thermally conductive substrates, and heat sink be stacked vertically, increasing the profile of the package and thereby making hermetic sealing of the solar package more difficult and expensive. A further limitation of solar packaging designs in current use is a maximum platform size of 4.5 inches×4.5 inches. An increased platform size would reduce the raw materials input required at the front end of the manufacturing process, ultimately increasing the capacity throughput.
SUMMARYAccording to the invention, a solar cell package is provided having a circular base and a ceramic ring that together form an individual sealed compartment to contain a solar cell, bypass diodes and other components required for a particular installation, which is preferably hermetically sealed, the entire structure being interchangeable and replaceable. In a specific embodiment the base has a separate and distinct support structure forming an individual sealed chamber containing the solar cell chip itself and optionally the bypass diodes and other components. Alternatively the bypass diodes and other components may be outside the hermetically sealed chamber. To achieve proper hermetic sealing of the solar cell chip, a cover is provided that has a clear window centrally located directly above the chip and hermetically sealed to the cover plate at its periphery by the ceramic ring in the chamber, the ring also being raised to define a reservoir to contain optical index matching fluid within the chamber and against the window. In still another embodiment, the hermetic cover and glass are omitted and replaced with a hermetic conformal coating that seals the components from the environment. Yet another embodiment does not employ hermetic sealing but takes advantage of some of the other unique features of the invention. A threaded mount is provided that allows for interchange and replacement of the package.
The invention will be better understood by reference to the following detailed description in connection with the accompanying drawings.
The embodiment of
The circular base 3 in this embodiment comprises three layers selected to provide good thermal conductivity and appropriately compatible CTEs. The upper layer 4 is a nonconductive surface onto which conductors, also called traces, 5 are deployed. In this embodiment, aluminum nitride is used as the nonconductor and an alloy of gold and silver iss used as the conductors, but those skilled in the art would readily recognize that other materials are available to achieve the same result. The middle layer 6 of the circular base 3 in the embodiment of
A threaded tubular pedestal aka threaded screw attachment 8, having a substantially flat upper surface, is brazed to the lower layer 7 of the circular base in good thermal contact for maximum heat transfer to a master heat sink (not shown). The screw attachment 8 allows for ease of manufacture of solar cell arrays that contain many such solar cell assemblies and also for ease of replacement of any cells that fail prematurely. Use of a threaded attachment mechanism also increases the surface area in contact with the master heat sink. Persons skilled in the art will recognize that there exist many alternative ways of attaching a solar cell package to a master heat sink for enhanced heat transfer and other purposes.
On the electrically nonconductive upper surface of the circular base, a deposited layer of conductive traces 5, a silver and gold alloy in this embodiment, is patterned to allow for electrical connections through wire bonding ribbons 9 for the output of solar cell 10. Solar cell 10 may be of many different types that are useful with CPV. In the embodiment of
Bonded to the nonconductive upper layer of the circular base, and forming a hermetic seal thereto, is an annular ring 12 creating a compartment containing the solar cell and bypass diodes, along with their various electrical connections. In the embodiment shown, the annular ring 12 is made of aluminum oxide, but those skilled in the art will recognize that other materials could be used with equal effectiveness. The upper surface of the annular ring is prepared and mounted to form an hermetic seal with metal cover 2.
A further embodiment is shown in
The invention has been explained with reference to specific embodiments. Other embodiments will be evident to those of ordinary skill in the art. Therefore, it is not intended that this invention be limited, except as indicated by the appended claims.
Claims
1. A low profile photovoltaic package, comprising
- a circular base, comprising: an upper layer comprising aluminum nitride, a middle layer comprising molybdenum, and a lower layer comprising oxygen-free, high-conductivity copper, wherein the upper layer, the middle layer, and the lower layer are characterized by a high and comparable coefficient of thermal expansion; the upper layer is electrically nonconductive; the middle layer and the lower layer are electrically conductive; and electrically conductive traces on a top surface of the upper layer;
- an annular ceramic ring hermetically sealed to the top surface with an epoxy or with an adhesive, wherein the annular ceramic ring is configured to form a compartment;
- a photovoltaic device mounted to the circular base within the compartment and electrically interconnected to the electrically conductive traces;
- bypass diodes mounted to the circular base, wherein the bypass diodes are interconnected to the photovoltaic device and to the electrically conductive traces;
- an externally threaded pedestal fixedly attached to a bottom surface of the lower layer;
- a cover, wherein the cover comprises: a quartz window comprising an outer diameter; and an iron-nickel-cobalt alloy disk characterized by a low thermal expansion coefficient and comprising an inner diameter.
2. The low profile photovoltaic package of claim 1, wherein the annular ceramic ring comprises aluminum oxide.
3. The low profile photovoltaic package of claim 1, wherein the circular base is characterized by a thickness of about 0.040 inches.
4. The low profile photovoltaic package of claim 1, wherein the electrically conductive traces comprise an alloy of gold and silver.
5. The low profile photovoltaic package of claim 1, wherein the threaded pedestal comprises exterior threads.
6. The low profile photovoltaic package of claim 1, wherein the hermetically sealed compartment is filled with an optical index matching fluid.
7. The low profile photovoltaic package of claim 1, wherein the bypass diodes are mounted to the circular base within the compartment.
3903427 | September 1975 | Pack |
4062698 | December 13, 1977 | Blakeslee et al. |
4180414 | December 25, 1979 | Diamond et al. |
4209347 | June 24, 1980 | Klein |
4491681 | January 1, 1985 | Kirpich |
4830678 | May 16, 1989 | Todorof et al. |
4999060 | March 12, 1991 | Szekely et al. |
5118361 | June 2, 1992 | Fraas et al. |
5460659 | October 24, 1995 | Krut |
5500052 | March 19, 1996 | Horiuchi et al. |
5935345 | August 10, 1999 | Kuznicki |
5944913 | August 31, 1999 | Hou et al. |
6281426 | August 28, 2001 | Olson et al. |
6623283 | September 23, 2003 | Torigian et al. |
6663982 | December 16, 2003 | Stephens et al. |
7449630 | November 11, 2008 | Ho et al. |
7514782 | April 7, 2009 | Hiramatsu et al. |
7727795 | June 1, 2010 | Stan et al. |
7851693 | December 14, 2010 | Fork et al. |
20030029497 | February 13, 2003 | Tanaka |
20040119149 | June 24, 2004 | Yin Pang et al. |
20050072457 | April 7, 2005 | Glenn |
20050155641 | July 21, 2005 | Fafard |
20060162768 | July 27, 2006 | Wanlass et al. |
20060163596 | July 27, 2006 | Kim et al. |
20060185716 | August 24, 2006 | Murozono et al. |
20060240599 | October 26, 2006 | Amano et al. |
20070089774 | April 26, 2007 | Lasich |
20070090517 | April 26, 2007 | Moon et al. |
20070240760 | October 18, 2007 | Gronet |
20070241450 | October 18, 2007 | Hiramatsu et al. |
20070290287 | December 20, 2007 | Freedman |
20080105298 | May 8, 2008 | Lu et al. |
20080150064 | June 26, 2008 | Zimmerman et al. |
20080185040 | August 7, 2008 | Tom et al. |
20080190480 | August 14, 2008 | Joshi |
20080315398 | December 25, 2008 | Lo et al. |
20090086478 | April 2, 2009 | Sanroma et al. |
20090120500 | May 14, 2009 | Prather et al. |
20090159126 | June 25, 2009 | Chan |
20090229659 | September 17, 2009 | Wanlass et al. |
20090255575 | October 15, 2009 | Tischler |
20090266395 | October 29, 2009 | Murthy et al. |
20090272438 | November 5, 2009 | Cornfeld |
20090298218 | December 3, 2009 | Federici et al. |
20100037935 | February 18, 2010 | Vaid et al. |
20100051085 | March 4, 2010 | Weidman et al. |
20100132765 | June 3, 2010 | Cumpston et al. |
20100139752 | June 10, 2010 | Fang |
20100180936 | July 22, 2010 | Kim |
20100294362 | November 25, 2010 | Christ et al. |
20100313954 | December 16, 2010 | Seel et al. |
20100326429 | December 30, 2010 | Cumpston et al. |
20100326492 | December 30, 2010 | Tan et al. |
20110030764 | February 10, 2011 | Seo et al. |
20110048535 | March 3, 2011 | Nagyvary et al. |
20110108113 | May 12, 2011 | Arikawa |
20110265871 | November 3, 2011 | Lamarche |
20120025618 | February 2, 2012 | Erickson, Jr. et al. |
20120199194 | August 9, 2012 | Lamarche et al. |
20120199195 | August 9, 2012 | Lamarche |
2254156 | November 2010 | EP |
2011/137305 | November 2011 | WO |
2011/106165 | August 2012 | WO |
2012/106160 | August 2012 | WO |
- “C10100 Oxygen-Free Copper”, Anchor Bronze & Metals, Inc., accessed at <https://web.archive.org/web/20080727020042/http://www.anchorbronze.com/c10100.htm> and dated Jul. 27, 2008.
- International Search Report and Written Opinion corresponding to the PCT application No. PCT/US2011/034485, date of mailing Aug. 3, 2011, 9 pages total.
- International Search Report and Written Opinion of the International Searching Authority for PCT Application No. PCT/US2012/022539, mailed on May 23, 2012, 10 pages.
- International Search Report and Written Opinion of the International Searching Authority for PCT Application No. PCT/US2012/022611, mailed on Jun. 21, 2012, 9 pages.
- Non-Final Office Action mailed on Dec. 19, 2012, for U.S. Appl. No. 13/224,204, 14 pages.
- Non-Final Office Action mailed on Mar. 14, 2013, for U.S. Appl. No. 13/092,555, 12 pages.
- Non-Final Office Action mailed on Nov. 21, 2013, for U.S. Appl. No. 12/944,361, 11 pages.
- Non-Final Office Action mailed on Dec. 11, 2013, for U.S. Appl. No. 13/092,555, 12 pages.
- Non-Final Office Action mailed on Dec. 19, 2012, for U.S. Appl. No. 13/224,204, 10 pages.
- Non-Final Office Action mailed on Mar. 14, 2013, for U.S. Appl. No. 13/224,204, 16 pages.
- Non-Final Office Action mailed on Dec. 20, 2013, for U.S. Appl. No. 13/224,181, 10 pages.
- International Preliminary Report on Patentability corresponding to the PCT Application No. PCT/US2011/034485, mailed on Nov. 15, 2012, 7 pages.
- International Search Report and Written Opinion corresponding to PCT Application No. PCT/US2011/036486, mailed on Aug. 25, 2011, 12 pages.
- International Search Report and Written Opinion corresponding to PCT Application No. PCT/US2010/056800, mailed on Jan. 26, 2011, 8 pages.
- Cotal et al., “III-V multijunction solar cells for concentrating photovoltaics”, Energy and Environment Science, Dec. 10, 2008, pp. 174-192.
- Friedman et al., “Breakeven Criteria for the GaInNAs Junction in GaInP/GaAs/GaInNAs/Ge Four-junction Solar Cells”, Progress in Photovoltaics: Research and Applications, 2002, pp. 331-344.
- Garcia et al., “Analysis of Tellurium As N-Type Dopant in GaInP: Doping, Diffustion, Memory Effect and Surfactant Properties”, Journal of Crystal Growth 298 2007, pp. 794-799.
- Geelen et al., “Epitaxial Lift-Off GaAs Solar Cell From a Reusable GaAs Substrate”, Materials Science and Engineering B45, 1997, pp. 162-171.
- Green, “Do Built-in Fields Improve Solar Cell Performance?”, Progress in Photovoltaics: Research and Applications, 2009, pp. 57-66.
- Jackrel et al., “Dilute nitride GainNAs and GainNAsSb solar cells by molecular beam epitaxy”, Journal of Applied Physics 101, 114916, 2007, pp. 1-8.
- Janotti et. al., “Mutual Passivation of Electrically Active and Isovalent Impurities in Dilute Nitrides”, Physical Review Letters 100, 2008, 045505.
- Ng et al., “1EV GANXAS1-X-YSBY Material for Lattice-Matched III-V Solar Cell Implementation on GAAS and GE”, Photovoltaic Specialists Conference (PVSC), 2009, 34th IEEE, pp. 76-80.
- Ptak et al., “Low-acceptor-Concentration GaInNAs grown by Molecular-beam Epitaxy for High-current p-i-n. solar cell applications”, Journal of Applied Physics 98, 2005, 094501.
- Volz et al., “Optimization of Annealing Conditions of (GaIn)(NAs) for Solar Cell Applications”, Journal of Crystal Growth 310, 2008, pp. 2222-2228.
- Wu et al., “Band Anticrossing in Highly Mismatched III-V Semiconductor Alloys”, Semiconductor Science and Technology 17, 2002, pp. 860-869.
- Yamaguchi et al., “Multi-junction III-V solar cells: Current status and future potential”, Solar Energy, Jul. 2005, vol. 79, Issue 1, Abstract only.
- Yu et. al., “Mutual Passivation of Group IV Donors and Nitrogen in Diluted GaNxAs1-x Alloys”, Applied Physics Letters, vol. 83, No. 14, Oct. 6, 2003, pp. 2844-2846.
- Notice of Allowance mailed on Jul. 8, 2014, for U.S. Appl. No. 13/224,204, 10 pages.
- Final Office Action mailed on Aug. 1, 2014 for U.S. Appl. No. 13/092,555, 13 pages.
- Final Office Action mailed on Jul. 31, 2013 for U.S. Appl. No. 13/224,181, 14 pages.
Type: Grant
Filed: Sep 1, 2011
Date of Patent: Feb 24, 2015
Patent Publication Number: 20120199196
Assignee: Solar Junction Corporation (San Jose, CA)
Inventor: Paul F. Lamarche (Morgan Hill, CA)
Primary Examiner: Jonathan Johnson
Assistant Examiner: Angelo Trivisonno
Application Number: 13/224,232
International Classification: H01L 31/00 (20060101); H01L 31/042 (20140101); H02N 6/00 (20060101); H01L 31/02 (20060101); H01L 31/052 (20140101);